Healing components for use in taking impressions and methods for making the same

ABSTRACT

The present invention provides a healing abutment for attachment to a dental implant with marking locations thereon. The marking locations either lack or have markers that provide a binary code system for retrieving unique information about the healing abutment and the underlying implant.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of prior U.S. patent application Ser.No. 12/156,753, filed Jun. 4, 2008, now allowed, which is a continuationof prior U.S. patent application Ser. No. 10/879,892, filed Jun. 21,2004, now U.S. Pat. No. 7,425,131, which is a continuation of prior U.S.patent application Ser. No. 10/007,997, filed Nov. 13, 2001, now U.S.Pat. No. 6,790,040, which is a continuation-in-part of prior U.S. patentapplication Ser. No. 09/710,208, filed Nov. 10, 2000, now U.S. Pat. No.6,558,162, which claims the benefit of U.S. Provisional PatentApplication No. 60/164,521, filed Nov. 10, 1999.

FIELD OF THE INVENTION

The present invention relates generally to a healing abutment in adental implant system. More particularly, the present invention relatesto the use of a binary marking system on the exterior of a healingabutment to identify unique characteristics of the healing abutment.

BACKGROUND OF THE INVENTION

The dental restoration of a partially or wholly edentulous patient withartificial dentition is typically done in two stages. In the firststage, an incision is made through the gingiva to expose the underlyingbone. An artificial tooth root, usually a dental implant, is placed inthe jawbone for integration. The dental implant generally includes athreaded bore to receive a retaining screw holding mating componentstherein. During the first stage, the gum tissue overlying the implant issutured and heals as the osseointegration process continues.

Once the osseointegration process is complete, the second stage isinitiated. Here, the gum tissue is re-opened to expose the end of thedental implant. A healing component or healing abutment is fastened tothe exposed end of the dental implant to allow the gum tissue to healtherearound. Preferably, the gum tissue heals such that the aperturethat remains generally approximates the size and contour of the aperturethat existed around the natural tooth that is being replaced. Toaccomplish this, the healing abutment attached to the exposed end of thedental implant has the same general contour as the gingival portion ofthe natural tooth being replaced. It should be noted that the healingabutment can be placed on the implant immediately after the implant hasbeen installed and before osseointegration.

During the typical second stage of dental restoration, the healingabutment is removed and an impression coping is fitted onto the exposedend of the implant. This allows an impression of the specific region ofthe patient's mouth to be taken so that an artificial tooth isaccurately constructed. Thus, in typical dental implant systems, thehealing component and the impression coping are two physically separatecomponents. Preferably, the impression coping has the same gingivaldimensions as the healing component so that there is no gap between theimpression coping and the wall of the gum tissue defining the aperture.Otherwise, a less than accurate impression of the condition of thepatient's mouth is taken. The impression coping may be a “pick-up”-typeimpression coping or a “transfer”-type impression coping, both known inthe art. After these second stage processes, a dental laboratory createsa prosthesis to be permanently secured to the dental implant from theimpression that was made.

In addition to the method that uses the impression material and mold tomanually develop a prosthesis, systems exist that utilize scanningtechnology to assist in generating a prosthesis. A scanning device isused in one of at least three different approaches. First, a scanningdevice can scan the region in the patient's mouth where the prosthesisis to be placed without the need to use impression materials or toconstruct a mold. Second, the impression material that is removed fromthe healing abutment and the surrounding area is scanned to produce thepermanent components. Third, a dentist can scan the stone model of thedental region that was formed from the impression material or scan thestone model.

Three basic scanning techniques exist: laser scanning, photographicimaging, and mechanical sensing. Each scanning technique is used ormodified for any of the above-listed approaches (a scan of the stonemodel, a scan of the impression material, or a scan in the mouth withoutusing impression material) to create the prosthesis. After scanning, alaboratory can create and manufacture the permanent crown or bridge,usually using a computer-aided design (“CAD”) package.

The utilization of a CAD program, as disclosed in U.S. Pat. No.5,338,198 (Wu), whose disclosure is incorporated herein by reference, isone method of scanning a dental region to create a three-dimensionalmodel. Preferably, after the impression is taken of the patient's mouth,the impression material or stone model is placed on a support tabledefining the X-Y plane. A scanning laser light probe is directed ontothe model. The laser light probe emits a pulse of laser light that isreflected by the model. A detector receives light scattered from theimpact of the beam with the impression to calculate a Z-axismeasurement. The model and the beam are relatively translated within theX-Y plane to gather a plurality of contact points with known locationsin the X-Y coordinate plane. The locations of several contact points inthe Z-plane are determined by detecting reflected light. Finally,correlating data of the X-Y coordinates and the Z-direction contactpoints creates a digital image. Once a pass is complete, the model maybe tilted to raise one side of the mold relative to the oppositevertically away from the X-Y plane. Subsequent to the model's secondscan, the model may be further rotated to allow for a more accuratereading of the model. After all scans are complete, the data may be fedinto a CAD system for manipulation of this electronic data by knownmeans.

Photographic imaging can also be used to scan impression material, astone model, or directly in the mouth. For example, one system takesphotographs at multiple angles in one exposure to scan a dental region,create a model, and manufacture a prosthetic tooth. As disclosed in U.S.Pat. No. 5,851,115 (Carlsson), whose disclosure is incorporated hereinby reference, this process is generally initiated with the process oftaking a stereophotograph with a camera from approximately 50 to 150 mmaway from the patient's mouth. The stereophotograph can involve aphotograph of a patient's mouth already prepared with implantationdevices. Correct spatial positioning of the dental implants is obtainedby marking the implant in several locations. The resulting photographpresents multiple images of the same object. The images on thephotographs are scanned with a reading device that digitizes thephotographs to produce a digital image of the dental region. The datafrom the scanner is electronically transmitted to a graphical imagingprogram that creates a model that is displayed to the user. Afteridentification of the shape, position, and other details of the model,the ultimate step is the transmission of the data to a computer formanufacturing.

A third scanning measure uses mechanical sensing. A mechanical contoursensing device, as disclosed in U.S. Pat. No. 5,652,709 (Andersson),whose disclosure is incorporated herein by reference, is another methodused to read a dental model and produce a prosthetic tooth. Theimpression model is secured to a table that may rotate about itslongitudinal axis as well as translate along the same axis with variablespeeds. A mechanical sensing unit is placed in contact with the model ata known angle and the sensing equipment is held firmly against thesurface of the model by a spring. When the model is rotated andtranslated, the sensing equipment can measure the changes in the contourand create an electronic representation of the data. A computer thenprocesses the electronic representation and the data from the scanningdevice to create a data array. The computer further compresses the datafor storage and/or transmission to the milling equipment.

SUMMARY OF THE INVENTION

The present invention is a healing abutment having a plurality ofexternal marking locations where markers are either present or absent.Due to the presence or absence of the markers, the physicalcharacteristics of the healing abutment are identifiable through use ofa binary-coded system. The present invention contemplates providing aset of healing abutments, each of which has unique physicalcharacteristics and a unique binary marking code that indicates thoseunique physical characteristics.

During the first or second stage of dental restoration, a healingabutment is non-rotationally fastened to the implant throughcomplimentary non-round fittings on the implant and abutment, whichusually take the form of a hexagonal boss and socket. The healingabutment is held on the implant via a screw that engages the threadedbore of the implant.

According to the invention, the presence or absence of the markers inthe marking locations may eliminate the need for an impression copingwithin the implant system. An impression can be taken of the mouth withthe markers creating features in the impression material. The impressionor a model of the impression is read or scanned such that the markersindicate various characteristics of the healing abutment and also theimplant. Further, such a system eliminates the need to remove thehealing abutment until the permanent components are ready to beinstalled in the patient's mouth.

Specifically, the presence or absence of the binary-coded markers in themarking locations allow the dentist to determine various physicalcharacteristics, such as the healing abutment height, healing abutmentdiameter, dimensions of the attached implant seating surface, and theorientation of the implant's fitting. It is contemplated in accordancewith one embodiment of the present invention that these markinglocations containing the binary-coded markers are preferably located onthe top of the healing abutment, although it may be possible to placesome markers on the side of the healing abutment.

In other embodiments of the present invention not using thisbinary-coded system, the information markers correspond to the height ofthe abutment to be captured in an impression or subsequent scan. Forexample, a 6 mm tall healing abutment may possess six informationmarkers on the top or side surface of the healing abutment. A 4 mm tallhealing abutment may possess four information markers, and a 2 mm tallhealing abutment may possess two information markers. This markingsystem may be altered to decrease the quantity of information markersrequired on the top or side surface of the healing abutment. Forexample, it is contemplated in accordance with the present inventionthat the use of three information markers on the top or side surface mayrepresent a 6 mm tall healing abutment, two information markers mayrepresent a 4 mm tall healing abutment, and one marker may represent a 2mm tall healing abutment.

It is also contemplated that the healing abutments of the presentinvention can be manufactured in sets of healing abutments, each sethaving healing abutments of the same diameter but different healingabutment heights. Different sets of healing abutments would have healingabutments with different diameters. For example, a first set of healingabutments may contain three healing abutments, one abutment of 2 mm, 4mm, and 6 mm height, respectively, and each with a diameter of 4 mm. Asecond set of healing abutments may also have abutments with heights of2 mm, 4 mm, and 6 mm, but these abutments may have a diameter of 5 mm.Information markers at one or more marking locations distinguish notonly between the first and second set of healing abutments, but alsobetween the three healing abutments within each set.

An impression of the mouth is taken with the inventive healing abutmentmounted on the implant. The impression process creates a “negative”image of the information markers in the impression material that changethe physical shape of the top or side surface. A corresponding mold iscreated from the impression. This mold, or a stone model created fromthe mold, can then be scanned. A computer program is able to create athree-dimensional perspective of the relevant jaw section of thepatient, including the implant and abutment. Due to the informationmarkers on the surface of the healing abutment now present in the mold,the computer program is able to accurately analyze and produce theappropriate dimensions of the aperture in the gingiva and theorientation of the underlying hexagonal boss of the implant so that aclinician can instruct a milling machine to produce the permanentcomponents.

In an alternative embodiment, the scanner simply takes the necessaryinformation directly from the mouth of a patient without the need forimpression material whatsoever. The information markers of the healingabutment provide the required information of the gingival aperture andthe orientation of the underlying hexagonal boss on the implant. If alaser or photographic scanning system is used, the etched markers areidentified just as easily as the markers that change the physical shapeof the healing abutment.

This system allows the dentist to produce the permanent components morequickly because the healing abutment does not have to be removed inorder to produce the permanent dental components. In other words, thesecond step of taking an impression with an impression coping iseliminated. The dentist also does not have to confront the difficultiesof gingival closure that appear when a healing implant is removed.Finally, the patient is not forced to endure the somewhat painfulprocedure of healing abutment removal. With the procedure of the presentinvention, the removal of the healing abutment can occur during the samesurgery as the installation of the permanent components.

In a further alternative embodiment, it is contemplated in accordancewith the present invention that an impression coping may possessinformation markers as described above and replace the standard healingabutment during second stage dental restoration surgery. The impressioncoping and surrounding environment are scanned directly in the mouth. Animpression could also be formed and a stone model produced from theimpression. This stone model is scanned to create the permanentprosthesis using one of the scanning techniques described above.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages of the invention will become apparentupon reading the following detailed description and upon reference tothe drawings.

FIG. 1 a is a top view of a healing abutment.

FIG. 1 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 1 a.

FIG. 1 c is the healing abutment shown in FIG. 1 b attached to animplant.

FIG. 2 a is a top view of another embodiment of a healing abutment.

FIG. 2 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 2 a.

FIG. 3 a is a top view of yet another embodiment of a healing abutment.

FIG. 3 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 3 a.

FIG. 4 a is a top view of a further embodiment of the healing abutment.

FIG. 4 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 4 a.

FIG. 5 a is a top view of another embodiment of a healing abutment.

FIG. 5 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 5 a.

FIG. 6 a is a top view of another embodiment of a healing abutment.

FIG. 6 b is a longitudinal cross-sectional view of the healing abutmentshown in FIG. 6 a.

FIG. 7 is an exploded view of another embodiment of the presentapplication.

FIG. 8 is a side view of a method for stereophotographic imaging.

FIGS. 9 a-9 p are top views of a plurality of healing abutments having abinary-type system of information markers.

FIG. 9 q is a top view of a healing abutment having a bar codeinformation marker.

FIG. 10 is a perspective view of a coordinate system of one embodimentof the present invention.

While the invention is susceptible to various modifications andalternative forms, specific embodiments have been shown by way ofexample in the drawings and will be described in detail herein. Itshould be understood, however, that the invention is not intended to belimited to the particular forms disclosed. Rather, the invention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

As shown in FIGS. 1 a and 1 b, the healing abutment 10 of one embodimentof the present invention has a main body 15 with a generally circularcross-sectional shape, a first tapered section 17, a boundary 19, asecond tapered section 21, an end surface 23, a hex socket 25, anddimensions that are generally suitable for replicating the emergenceprofile of a natural tooth. The first tapered section 17 extendsdownward from the main body 15 of the abutment 10, having a diameter ata boundary 19 that is generally larger than the implant (not shown). Theboundary 19 separates the first tapered section 17 from the secondtapered section 21 that terminates in the end surface 23. The secondtapered section 21 is at an angle with the central axis of the implantthat is generally in the range of from about 5° to about 15°, with 10°being preferable. Alternatively, the second tapered section 21 may beomitted such that the first tapered section 17 tapers directly to thediameter of the end surface 23 of the implant. In a further embodiment,the first tapered section 17 may merge smoothly into the second taperedsection 21, without the distinct boundary 19 separating the two taperedsections 17, 21. The hexagonal orientation socket or hex 25 is formating with a hexagonal boss on the implant. The end surface 23 hasgenerally the same diameter as the seating surface of the implant.

FIG. 1 b discloses the top view of the same healing abutment 10 shown inFIG. 1 a. As shown in FIGS. 1 a and 1 b, the healing abutment 10 haspositive information markers 20 protruding from a top surface 29 of thehealing abutment 10. Each of the six positive information markers 20 isdisposed such that it aligns with the six corners of the underlying hex25. It is also contemplated in accordance with the present inventionthat the six information markers 20 may also correspond to the height ofthe healing abutment. For example, two information markers maycorrespond to a 2 mm tall healing abutment and four information markersmay correspond to a 4 mm tall healing abutment. In these embodiments,the two or four information markers would still be at the corners of theunderlying hex 25 so that the relative position of the hex is known.

A socket 30 on the exposed surface of a head portion 40 of an attachingbolt 50 is shaped to accept a wrench (not shown) for turning theattaching bolt 50 into the threaded bore of an implant 70, as shown inFIG. 1 c. It is contemplated in accordance with the present inventionthat each of the healing abutments described herein and shown in thefigures can be secured to an implant by means of an attaching bolt, asis known in the art. An O-ring 60 carried on the head portion 40 of theattaching bolt 50 fills an annular gap left between the head and theentrance section near the outermost (widest) opening in the entrancesection.

A healing abutment 100 of FIG. 2 a comprises many of the same featuresas the healing abutment 10 shown in FIG. 1 a. Dashed lines 125 in FIG. 2b correspond to the underlying hex 125 of the healing abutment 100 inFIG. 2 a. A top surface 129 includes negative information markers(recesses) 120 that are displayed in FIG. 2 a as dimples extending belowthe top surface 129 of the healing abutment 100. The top surface 129 ofthe healing abutment 100 also possesses six notches 130 that aremachined into the corners. The top surface 129 is generally flat andmerges into a rounded shape at the periphery of the healing abutment100.

The notches 130 are used, for example, to determine the identificationof the underlying implant hex position 125, the height of the healingabutment, or the diameter of the healing abutment. This embodiment isnot limited to comprising six notches in the top surface 129 of thehealing abutment 100. It is also contemplated that one embodiment of thepresent invention may possess four notches or even two notches forindicative purposes. Furthermore, it is contemplated that theinformation marker and notch approach could be combined or modified toprovide information regarding the underlying implant seating surfacediameter and implant hex angulation.

In another embodiment of the present invention, a healing abutment 200shown in FIGS. 3 a and 3 b displays four positive information markers220 shown to, for example, indicate a 4 mm tall healing abutment 200. Itis contemplated that the number of information markers 220 coulddecrease or increase depending on the height of the healing abutment 200or another variable that the information markers have been designated tocorrespond. The positive information markers 220 also define acorresponding one of the six flat surfaces of an underlying hex 225.Furthermore, dashed lines 225 in FIG. 3 b correspond directly to theunderlying hex 225.

Two notches 230 have also been etched or machined onto a top surface 229of the healing abutment of FIG. 3 b. These notches may indicate thediameter of the implant's seating surface. Lines 240 are scribed on thetop surface 229 of the healing abutment 200. The lines 240 are used toprovide positioning or other information to the dentist or laboratory.Here, the lines 240 indicate the diameter of the healing abutment (e.g.,4 mm). In summary, the number of the positive information markers 220indicates the height of the healing abutment 200. The position of thepositive information markers 220 indicates the orientation of the hex225 that is the orientation of the hexagonal boss on the implant. Thenotches 230 indicate the diameter of the seating surface of the implant.The lines 240 indicate the diameter of the healing abutment 200.

In yet another embodiment of the present invention, a top surface 329 ofthe healing abutment 300 of FIGS. 4 a and 4 b comprises an etched ormachined hex 335. Corners 322 of the etched hex 335 correspond directlyto the position of the corners of an underlying hex 325 shown in FIG. 4a. It is contemplated in accordance with one embodiment of the presentinvention that further information markers may be added to the healingabutment for the dentist or laboratory to ascertain different heights ordiameters.

A top surface 429 of a healing abutment 400 shown in FIGS. 5 a and 5 bcontains an etched or machined triangle 435. Dashed lines 425 in FIG. 5b indicate the location of an underlying hex 425. Corners 422 of theetched triangle 435 correspond to three of the six corners of theunderlying hex 425. Furthermore, two negative information markers 420are shown in FIG. 5 b. As above, it is contemplated in accordance withthe present invention that fewer than six information markers may existto account for differing heights or diameters of the healing abutments.

Another embodiment of the present invention is shown in FIGS. 6 a and 6b. The healing abutment 500 displayed in FIGS. 6 a and 6 b is a shorterversion of the healing abutment 10 shown in FIGS. 1 a and 1 b. Twopositive information markers 520 are shown in FIG. 6 b to identify theheight of the healing abutment 500. Dashed lines 525 of the healingabutment 500 correspond with the location and orientation of theunderlying hex 525. Two notches 530 are also shown in a top surface 529of this embodiment of the present invention to show the orientation oftwo of the underlying flats of the underlying hex 525. A numeral “4” at537 is located on the top surface 529 of the healing abutment 500 toindicate, for example, the diameter of the healing abutment 500. Asshown, the numeral “4” at 537 corresponds to a healing abutment 500 witha diameter of 4 mm. It is contemplated in accordance with the presentinvention that other numerals could be placed on the top surface 529 ofthe healing abutment 500 to indicate other healing abutment diameters.Further, it is also contemplated that the numeral could represent theheight of the healing abutment or the diameter of the underlyingimplant.

During the second stage of the prosthetic implementation process andafter a healing abutment with the information markers has been placed,an impression of the mouth is made with only the healing abutments asdescribed herein and without the use of an impression coping. A model ofthe impression is poured with, for example, die stone. Since theinformation markers are disposed on the top and/or side of the healingabutment, the laboratory has all necessary information to define thegingival aperture, the implant size, and the orientation of theunderlying hex. This enables the laboratory to quickly prepare thepermanent components. The system of the present invention also allowsthe maintenance of the soft tissue surrounding the healing abutmentwhere, in prior systems, the soft tissue would close once the healingabutment was removed. The system spares the patient the pain of removingthe healing abutment.

To create a permanent prosthesis, the dental region is scanned, asdescribed above, from a stone model, from the impression material, ordirectly in the mouth using a laser scanning technique, a photographicscanning technique, or a mechanical sensing technique. FIG. 8 showsstereophotographic imaging, one method used for scanning.Stereophotography with a camera 703 is performed directly on the mouthcavity 705 of the patient 707. A clinician can photograph implants andother components that have been placed into or adjacent the patient'sjawbone 709.

The scanned information is then transferred into a graphical imagingprogram for analysis. The graphical imaging software program, due to theinformation markers on the surface of the healing abutment, can performa wide variety of functions. The graphical imaging program can scan anopposing cast in order to develop an opposing occlusal scheme and relatethis information back to the primary model. This feature is extremelyimportant because many clinical patients have implants in both maxillaryand mandibular locations.

The graphical imaging software program is capable of generating athree-dimensional image of the emergence profile contours used on thehealing abutment. If the implant is not placed in the desired estheticlocation, the software program relocates the position of the restorationemergence through the soft tissue. The graphical imaging softwareprogram is also able to accurately relate the gingival margin for allmold, model, implant, and abutment dimensions. The software creates atransparent tooth outline for superimposition within the edentuloussite. The occlusal outline of the “ghost” tooth should, if possible, beaccurate and based on the scanned opposing occlusal dimensions. It iscontemplated in accordance with the present invention that an occlusaloutline is created by scanning a wax-up in order to maintain a properplane of occlusion and healing abutment height.

The software program subtracts a given dimension from the mesial,distal, buccal, lingual, and occlusal areas of the superimposed toothdimension. This allows for an even reduction of the healing abutmentduring fabrication for proper thickness of the overlying materials(e.g., gold, porcelain, targis, etc.). The graphical imaging softwareprogram also incorporates angulation measurements into the customabutment and subsequently calculates the dimensions of the prosthesisthat are checked and modified, if necessary, by a laboratory technician.Each of the features is analyzed and determined from the differentinformation markers that exist on the healing abutments of the presentinvention.

The final dimensional information determined by the graphical imagingcomputer program is transferred from the computer to a milling machine(e.g., a 5 axis milling machine) to fabricate the custom abutment. It iscontemplated in accordance with the present invention that the customabutment can be fashioned from gold or titanium or other similar metalsor composites. A custom milled coping can then be fabricated. It iscontemplated in accordance with the present invention that the custommilled coping can be formed from titanium, plastic, gold, ceramic, orother similar metals and composites.

FIG. 7 shows the exploded view of another embodiment of the presentinvention. A cap 602 is placed on a healing abutment 600 and laterremoved during the process of taking the impression of the healingimplant and surrounding features of the patient's mouth. It iscontemplated in accordance with the present invention that the cap 602could be formed from plastic or metal or a composite material. As shownin FIG. 7, notches 604 are formed in the side(s) of the healing abutment600. These notches correspond to notches 606 that have been preformed inthe cap 602. When the cap 602 is placed on the healing abutment 600, thecap only fits snugly and properly if the number of notches 606 in thecap 602 correspond exactly to the number of notches 604 in the sidewall(s) of the healing abutment. It is contemplated in accordance withthe present invention that there could be many less or more notches thanis depicted in FIG. 7. These notches correspond to informationparameters such as healing abutment height, healing abutment, and/orimplant diameter, and other parameters as listed above.

Specifically, after the healing abutment has been secured to theimplant, the cap 602 is securely placed over the top of the healingabutment 600. The impression material is then placed over the top of thecap 602. The impression is then either scanned in the patient's mouth orthe impression material (with the cap 602) is scanned and the processcontinues as described above.

FIGS. 9 a-9 p depict yet another embodiment of the present invention.Specifically, FIGS. 9 a-9 p show the top view of a plurality of healingabutments, each of which has four marking locations on the top surfaceof the healing abutment. For each healing abutment, a marker is eitherpresent or absent in each of the four marking locations, and thepresence or absence can be interpreted either visually or by a scanningdevice. As explained below in detail, the markers in the markinglocations permit identification of healing abutment characteristics,such as dimensions of the healing abutment.

In FIGS. 9 a-9 p, the four rows correspond to four different healingabutment heights (e.g., 3 mm, 4 mm, 6 mm, and 8 mm). The four columns ofthe coding key correspond to four different diameters of the healingabutment seating surfaces (e.g., 3.4 mm, 4.1 mm, 5.0 mm, and 6.0 mm).Accordingly, sixteen unique healing abutments are present.

The top surface of each of the healing abutments has from zero to fourinformation markers located in the four marking locations. As shown inFIGS. 9 a-9 p, the marking locations extend radially from a centralregion of the healing abutment to the outer region of the top surface ofthe healing abutments (i.e., at locations of 12 o'clock, 3 o'clock, 6o'clock, and 9 o'clock).

As is well known, a binary-coded system exists as an array of digits,where the digits are either “1” or “0” that represent two states,respectively, ON and OFF. For each marking location, the presence of amarker (“ON”) is a 1 and the absence of a marker (“OFF”) is a 0. Bygrouping sets of 1's and 0's together, information about each healingabutment is known. In the illustrative embodiment, the determination ofthe sets of 1's and 0's derived from the information markers (e.g., viavisual inspection, scanning in the mouth, scanning of the impression, orscanning of the model created by the impression) provide information onthe height of the healing abutment and the diameter of the seatingsurface of the attached implant.

The information markers shown in FIGS. 9 a-9 p are in the form ofgrooves having rounded cross-sections. The present invention, however,provides that the cross-section of these grooves can be rectangular,triangular, or various other shapes. When an impression is created fromthe healing abutment, the grooved marking locations produce a protruding“mound”-like element in the impression. This impression is then scannedso that identifying features regarding the healing abutment can beobtained. Alternatively, a model of the patient's mouth is created fromthe impression such that the markings are again grooves in the modelthat substantially replicate the grooves in the healing abutments. Ofcourse, the markers could also be protrusions instead of grooves.Further, if the unique characteristics of the healing abutment are to beidentified through scanning in the mouth or simply visual scanning bythe clinician, then markers not producing features in impressionmaterial, such as etched or laser marking, may also be used.

Turning now to the specifics of each healing abutment, FIG. 9 aillustrates a top view of a healing abutment 801 that includesorientation pick-ups 802. These orientation pick-ups 802 are alsopresent in each of the healing abutments shown in FIGS. 9 b-9 p. Themost counterclockwise of the orientation pick-ups 802 (i.e., thehorizontal pick-up at the lower region of FIGS. 9 a-9 p) is alwaysparallel to one flat of the implant hex, as viewed from the top of thehealing abutment. As shown, the orientation pick-ups 802 are a pair ofbevels on the sides of the healing abutments in FIGS. 9 a-9 p.Alternatively, the orientation pick-ups 802 can be grooves or protrudingridges, as well.

The orientation pick-ups 802 serve a second function in that theydictate which of the four marking locations is the first markinglocation. The other three marking locations are then read in clockwiseorder, proceeding from the most counterclockwise pick-up 802 to theother three marking locations on the top surface of the healingabutment. In other words, as illustrated in FIGS. 9 a-9 p, theinformation marker at 6 o'clock is the first digit in the binary code,the information marker at 9 o'clock is the second digit in the binarycode, the information marker at 12 o'clock is the third digit in thebinary code, and the information marker at 3 o'clock is the fourth digitin the binary code. In summary, the position of the orientation pick-ups802 allows for the determination of the position of one of the hex flatsof the healing abutment (and, likewise, one of the hex flats on theimplant), and also the starting point to check for the presence orabsence of information markers.

The results of a scan (computer or visual) of the four informationmarkers on the healing abutment 801 produce no information markers atthe four marking locations on the healing abutment 801 of FIG. 9 a.Thus, the binary code for the healing abutment 801 is 0000, indicatingthat no grooved marker is present in any of the four predeterminedpositions. Since the coding key is preset (on a chart or in computersoftware), the binary code 0000 indicates that the healing abutment 801is a resident of first row and first column of the matrix depicted byFIG. 9, having a height of 3 mm and a seating surface diameter of 3.4mm. Thus, the three distinct pieces of information obtained from the topof the healing abutment allow the clinician or laboratory to know (i)the orientation of the hex of the implant, (ii) the height of thehealing abutment (i.e., the location of the implant's seating surfacebelow the healing abutment), and (iii) the seating surface diameter ofthe healing abutment (or the size of the implant's seating surface).

The healing abutment 806 in FIG. 9 b possesses a binary code of 0100because only one information marker 807 is present in the second markinglocation. Thus, it is understood from the binary code that the healingabutment 806 is 3 mm in height and has a seating surface diameter of 4.1mm. The two healing abutments 811, 816 in FIGS. 9 c, 9 d have binarycodes of 1000 and 1100, respectively. Healing abutment 811 has aninformation marker 812 in the first marking location, while healingabutment 816 has information markers 817, 818 in the first twolocations. Thus, the unique characteristics of these two healingabutments are known.

The healing abutments 821, 826, 831, 836 shown in FIGS. 9 e-9 h andhaving heights of 4 mm, but with varying seating surface diameters,would be interpreted as having binary codes 0010, 0110, 1010, and 1110,respectively. Healing abutment 821 has one information marker 822present in the third marking location, thus resulting in a binary codeof 0010, which is indicative of a healing abutment height of 4 mm and aseating surface diameter of 3.4 mm. Similar analyses on healing abutment826 with information markers 827, 828, healing abutment 831 withinformation markers 832, 833, and healing abutment 836 with informationmarkers 837, 838, 839 allow determinations of the unique characteristicsof these healing abutments.

The healing abutments 841, 846, 851, 856 shown in FIGS. 9 i-9 l andhaving heights of 6 mm, but with varying seating surface diameters,would be interpreted as having binary codes 0001, 0101, 1001, and 1101,respectively. Healing abutment 841 has one information marker 842present in the fourth marking location, thus resulting in a binary codeof 0001, which is indicative of a healing abutment height of 6 mm and aseating surface diameter of 3.4 mm. Similar analyses on healing abutment846 with information markers 847, 848, healing abutment 851 withinformation markers 852, 853, and healing abutment 856 with informationmarkers 857, 858, 859 allow determinations of the unique characteristicsof these healing abutments.

The healing abutments 861, 866, 871, 876 shown in FIGS. 9 m-9 p andhaving heights of 8 mm, but with varying seating surface diameters,would be interpreted as having binary codes 0011, 0111, 1011, and 1111,respectively. Healing abutment 861 has two information markers 862, 863,which is indicative of a healing abutment height of 8 mm and a seatingsurface diameter of 3.4 mm. Similar analyses on healing abutment 866with information markers 867, 868, 869, healing abutment 871 withinformation markers 872, 873, 874, and healing abutment 876 withinformation markers 877, 878, 879, 880 allow determinations of theunique characteristics of these healing abutments.

While the matrix of the sixteen healing abutments in FIGS. 9 a-9 p showfour implant seating surface diameters and four heights, the matrixcould include other physical characteristics of the healing abutment.For example, the maximum diameter of the healing abutment could beinformation obtainable through the binary-coded system. The type offitting on the healing abutment and, thus, the implant (i.e., internalhex or external hex) could be provided. Information unrelated to thehealing abutment, but related to only the implant, could be used. Forexample, the manufacturer of the implant could be noted. Or, informationregarding the type of screw that mates with the internally thread boreof the implant could be provided.

Further, while FIGS. 9 a-9 p demonstrate the ability of the four digit,binary-coded system to provide two physical characteristics of thehealing abutment, it could provide three or more physicalcharacteristics. For example, two seating surface sizes, four heights,and two maximum diameters would provide sixteen unique healingabutments. If more information were needed, a fifth marking locationcould be added to provide the opportunity for displaying thirty-twophysical characteristics of the healing abutments and/or implant. And,while one marking location has been shown with marker, it is possible tohave two or more markers in each marking location. For example, onecircumferential groove and one radial groove within one location couldrepresent two digits of a binary system. Alternatively, having twowidths possible for each groove could provide additional indiciarepresentative of certain information about the healing abutment.

While the invention has been described with round healing abutments,healing abutments anatomically shaped like teeth can take advantage ofthe information markers. Thus, the set of healing abutments couldinclude components shaped like the various teeth, and the informationmarkers could provide the information regarding which tooth shape ispresent on the healing abutment. For example, a set may include fourtypes of molar-shaped healing abutments, four types of bicuspid-shapedhealing abutments, four types of incisor-shaped healing abutments andfour types of round abutments. The four information marker locations oneach component in the set provide the information to determine which oneof the sixteen healing abutments is being used.

It is contemplated that the present invention also covers a set of eightunique healing abutments (as opposed to the sixteen shown) requiringonly three marking locations. The computer software and/or the visualchart in this situation would identify these eight unique healingabutments through binary codes possessing three digits. The potentialbinary codes corresponding to an ON or OFF determination at the threemarking locations are 000, 100, 010, 001, 110, 101, 011, and 111.Similarly, if the set has only four unique healing abutments, only twomarking locations would be required on the healing abutments todetermine features regarding the healing abutment and the attacheddental implant. The potential binary codes in a four healing abutmentmatrix are 00, 10, 01, and 11.

After the top surface of a healing abutment (or the impression of thetop surface, or the model of the impression of the top surface) isanalyzed, the orientation of the hex is known from the location of theorientation pick-ups 802 and, via the binary code, the abutment heightand the seating surface of the healing abutment is known. Otherinformation regarding the healing abutment and the attached implant canalso be determined by adding other markers of the type previously shown.

In addition to the markers described, it is further possible to providea bar-coded system for providing information about the particularcomponent, as shown in FIG. 9 q. The bar code 894 can be located on thetop surface on the healing abutment 892 such that it can be scanned orread easily. Thus, the bar code 894 would provide the same type ofinformation described above with respect to the information markers.

Referring to FIG. 10, when scanning techniques are used to learn of theinformation on the top of the healing abutment, the computer software isable to determine the position and orientation of the implant 900relative to the adjacent teeth. The position of the implant 900 isdefined in a Cartesian coordinate system having “X,” “Y,” and “Z” axes.The common point is at the intersection of the centerline of the implantand a plane 920 representing the seating surface 925 of the implant 900.

As noted above, the information markers assist in determining the heightof the healing abutment above the implant. This height can be used toidentify the zero point on the “Z” axis, which is in the plane 920containing the seating surface 925 of the implant 900. The “Y” axis 910is within the plane 920 representing the seating surface 925 with thepositive “Y” direction as close to the direction of facial to buccal aspossible. The “X” axis 915 is in the plane 920 and is perpendicular toan implant hex face. Thus, the width of the seating surface 925 in theplane 920 is known, as is the width of the healing abutment emergingthrough the gingiva. Thus, the emergence profile of the artificial toothis known, as well.

While the present invention has been described with reference to one ormore particular embodiments, those skilled in the art will recognizethat many changes may be made thereto without departing from the spiritand scope of the present invention. Each of these embodiments andobvious variations thereof is contemplated as falling within the spiritand scope of the present invention, which is set forth in the claimsthat follow.

1. A method of developing a custom abutment, comprising: attaching anattachment member to a dental implant in a mouth of a patient, theattachment member being a unitary member and including a top surfacecomprising at least one feature indicative of first and secondcharacteristics of the dental implant, the attachment member beingconfigured to mate with only the dental implant when the attachmentmember is attached to the dental implant such that the top surface ofthe attachment member is free to be directly scanned; scanning at leastan area of the mouth including the attachment member to generate scandata; determining the first and second characteristics of the dentalimplant using the scan data; and developing custom-abutment dimensionalinformation based at least in part on the determined characteristics ofthe dental implant.
 2. The method of claim 1, wherein the attachmentmember is a gingival healing abutment.
 3. The method of claim 1, whereinat least one of the first and second characteristics is informationregarding a location of the dental implant.
 4. The method of claim 1,wherein at least one of the first and second characteristics isinformation regarding a location of a polygonal fitting of the dentalimplant.
 5. The method of claim 1, wherein the first and secondcharacteristics include information regarding a location of the dentalimplant and an orientation of a polygonal fitting of the dental implant.6. The method of claim 1, wherein the scanning is a photographicscanning technique.
 7. The method of claim 1, further comprisingfabricating the custom abutment utilizing the developed custom-abutmentdimensional information.
 8. The method of claim 1, wherein the at leastone feature on the attachment member is at least one binary-coded markerfeature.
 9. The method of claim 1, wherein the at least one feature onthe attachment member is one of the group selected from positiveinformational markers, negative informational markers, and a notch. 10.A method of manufacturing a custom dental abutment for mating with adental implant installed in a mouth of a patient, comprising: attachingan attachment member to the dental implant, the attachment member havingan upper surface with features that indicate at least twocharacteristics of the dental implant installed in bone of a patient,the attachment member being configured to mate with only the dentalimplant when the attachment member is attached to the dental implantsuch that the upper surface of the attachment member is free to bedirectly scanned in the mouth of the patient; scanning at least aportion of the mouth that includes the attachment member having theupper surface with the features; generating scan data from the scanningof the at least a portion of the mouth; creating a three-dimensionalimage of the at least a portion of the mouth with the scan data;determining the features of the attachment member to gather informationof the at least two characteristics of the dental implant; anddeveloping custom-abutment dimensional information based on thethree-dimensional image and the information gathered from the features.11. The method of claim 10, further comprising fabricating the customdental abutment utilizing the custom-abutment dimensional information.12. The method of claim 10, wherein the attachment member is a gingivalhealing abutment.
 13. The method of claim 10, wherein the features onthe attachment member are binary-coded marker features.
 14. The methodof claim 10, wherein the features on the attachment member are one ofthe group selected from positive informational markers, negativeinformational markers, and a notch.
 15. The method of claim 10, whereinat least one of the characteristics is information regarding a locationof the dental implant.
 16. The method of claim 10, wherein at least oneof the characteristics is information regarding a location of apolygonal fitting of the dental implant.
 17. The method of claim 10,wherein the at least two characteristics include information regarding alocation of the dental implant and an orientation of a polygonal fittingof the dental implant.
 18. The method of claim 10, wherein the scanningis a photographic scanning technique.
 19. A method of creating a customabutment for attachment to a dental implant in a mouth of a patient,comprising: preparing the mouth for three-dimensional modeling, themouth at least including teeth, gingival tissue, the dental implant, andan attachment member coupled to the dental implant, the attachmentmember having at least one informational marker that indicatesinformation regarding characteristics of the dental implant; creating athree-dimensional model of at least a portion of the mouth including theattachment member; creating a modified three-dimensional model includinga three dimensional model of the custom abutment; and designing thecustom abutment from the modified three-dimensional model.
 20. Themethod of claim 19, further comprising transmitting the modifiedthree-dimensional model to a milling machine capable of producing thecustom abutment.
 21. The method of claim 20, further comprisingproducing the custom abutment using the milling machine.
 22. The methodof claim 21, further comprising placing a prosthetic tooth over theproduced custom abutment.
 23. The method of claim 22, further comprisingsecuring the custom abutment to the dental implant in the mouth.
 24. Themethod of claim 19, wherein the attachment member is a unitary memberand includes a top surface having the at least one informational marker.25. The method of claim 24, wherein the attachment member is configuredto mate with only the dental implant in response to the attachmentmember being coupled to the dental implant such that the top surface ofthe attachment member is free to be scanned directly.
 26. The method ofclaim 19, wherein the dental implant has an exposed end to which theattachment member is coupled and an end implanted in a jawbone of thepatient.
 27. The method of claim 26, wherein the preparing the mouth forthree-dimensional modeling includes placing the attachment member on theexposed end of the dental implant.
 28. The method of claim 19, whereinthe preparing the mouth for three-dimensional modeling includes: (i)installing the dental implant within a jawbone of the patient, thedental implant having an exposed end and an end implanted in thejawbone; and (ii) placing the attachment member on the exposed end ofthe dental implant.
 29. The method of claim 19, wherein the creating amodified three-dimensional model includes determining the location anddimensions of the dental implant based on the information from the atleast one informational marker.
 30. The method of claim 29, wherein thelocation of the dental implant provides an orientation of anon-rotational feature of the dental implant.